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INSTRUCTIONS
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the M
ARZOCCHI
2. On reassembling the suspension system,
always use new seals.
3. Clean all metal parts with a special,
preferably biodegradable solvent, such
as trichloroethane or trichloroethylene.
4. Before reassembling, lubricate all parts
in contact with each other using silicone
fat spray or a specific oil for seals.
5. Always grease the lip seal rings before
reassembling.
EXR
6. Use wrenches with metric size only.
Wrenches with inch size might damage
Coil
the fastening devices even when their
size is similar to that of the wrenches in
metric size.
special tools only.
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Table of Contents
Related Manuals for Marzocchi EXR Coil
Summary of Contents for Marzocchi EXR Coil
- Page 1 INSTRUCTIONS GENERAL RULES 1. Where specified, assemble and disas- semble the shock absorption system us- ing the M special tools only. ARZOCCHI 2. On reassembling the suspension system, always use new seals. 3. Clean all metal parts with a special, preferably biodegradable solvent, such as trichloroethane or trichloroethylene.
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Page 2: Failures, Causes And Remedies
FAILURES, CAUSES AND REMEDIES This paragraph reports some failures that may occur when using the fork. It also indicates possible causes and suggests a remedy. Always refer to this table before doing any repair work. FAILURES CAUSES REMEDIES Oil leaking though the top of slider 1. -
Page 3: Recommendations For Maintenance
RECOMMENDATIONS FOR INSTALLATION MAINTENANCE Installing the fork on a bicycle is a very DISC BRAKE SYSTEM ASSEMBLY delicate operation that should be carried forks are based on advanced WARNING: If a disc brake system ARZOCCHI out with extreme care. The installation should technology, supported by year-long experi- is installed, it is possible to replace always be checked by one of our Technical... -
Page 4: Spring Preload
ADJUSTMENT SPRING PRELOAD Take off the rubber protection (2). To change preload, turn the screw (4) inside cap (5) using a 4 mm Allen wrench. Turn out the screw (4) completely, then tighten it until it touches the upper washer (7). -
Page 5: Disassembly Diagram
DISASSEMBLY GENERAL – The reference numbers given in this section relate to the components shown in the fork exploded view. – Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling sequence. Locate the part you need to remove in the diagram, then look at the arrows to determine which other parts you need to remove first. - Page 6 SPRING CHANGE FIG. 2 SEAL ASSEMBLY CHANGE FIG. 1 Push the stanchions into the sliders and FIG. 3 Unscrew the caps (5) with a 21 mm socket remove the lower washer (7) and the Turn the fork leg upside-down and unscrew wrench.
- Page 7 FIG. 4 FIG. 5 FIG. 6 Withdraw the crown and stanchions as- Remove the dust seal (15) from the top of Remove the stop ring (16) from the sliders sembly (1) from the sliders (18). the sliders using a small screwdriver. by placing the screwdriver bit in one of the three openings on the stop ring.
- Page 8 FIG. 7 FIG. 8 VALVE ASSEMBLY CHANGE Fit the slider protector (A) onto the slider Withdraw the pumping elements (10) and FIG. 9 and remove the oil seal (17) with the help the rebound spring (11) from the stanchion To check that the valve assembly is operat- of a large screwdriver.
- Page 9 REASSEMBLY FIG. 11 FIG. 12 Insert the stop ring (16) into the slider Lubricate the dust seals (15) and fit them CAUTION: before reassembling, all metal making sure it is properly seated into place. into the stanchions from the spring end. components should be washed carefully Use buffer (B) to properly seat the ring into with inflammable, preferably biodegrad-...
- Page 10 VALVE AND PUMPING ROD FIG. 14 CROWN AND STANCHIONS ASSEMBLY Fit this assembly into the stanchion tube and ASSEMBLY FIG. 13 properly seat the valve assembly (C). FIG. 15 Fit the crown and stanchions assembly (1) After having overhauled or replaced the Insert the stop ring (22).
- Page 11 FIG. 16 HOW TO FILL WITH OIL SPRING AND CAP Grease the O-ring (19) on the foot nut (20) FIG. 17 FIG. 18 and screw the nut on the pumping rod Pour oil little by little when the stanchions Fit the spring (8) and washer (7) into each thread (10).
- Page 12 FIG. 19 Lubricate the O-ring (6) on the cap (5). Turn the preload adjuster (4) inside the cap until setting minimum preload (see section ADJUSTMENT). Start the complete cap assembly into the stanchion tube thread by hand. Tighten the cap (5) to 20 Nm. Set spring preload as specified in section ADJUSTMENT.
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